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INSTALLATION INSTRUCTIONS

Genset Controller, AGC 100


Mounting
Terminal overview
Wiring
Communication wiring
Unit dimensions and cutout

DEIF A/S Frisenborgvej 33 DK-7800 Skive Tel.: +45 9614 9614 Fax: +45 9614 9615 info@deif.com www.deif.com
isenborgvej 33 DK-7800 Skive Tel.: +45 9614 9614 Fax: +45 9614 9615 info@deif.com www.deif.com Document no.: 4189340752C
14 9614 Fax: +45 9614 9615 info@deif.com www.deif.com SW version: 4.0x.x
AGC 100 installation instructions
4189340752 UK

1. General information
1.1. Warnings, legal information and safety..................................................................................................3
1.1.1. Warnings and notes ......................................................................................................................3
1.1.2. Legal information and disclaimer ..................................................................................................3
1.1.3. Safety issues ................................................................................................................................3
1.1.4. Electrostatic discharge awareness ...............................................................................................3
1.1.5. Factory settings ............................................................................................................................3
1.1.6. UL applications..............................................................................................................................4
1.2. About the installation instructions...........................................................................................................4
1.2.1. General purpose ...........................................................................................................................4
1.2.2. Intended users ..............................................................................................................................4
1.2.3. Contents and overall structure ......................................................................................................4

2. Mounting
2.1. AGC 100 mounting.................................................................................................................................5
2.1.1. Unit dimensions and panel cutout..................................................................................................5
2.1.2. Tightening torques.........................................................................................................................6

3. Terminals
3.1. Terminal overview and description.........................................................................................................7
3.1.1. Terminal description......................................................................................................................7

4. Wiring
4.1. Wiring diagram.....................................................................................................................................11
4.2. DC connections....................................................................................................................................12
4.3. Digital inputs.........................................................................................................................................13
4.4. Breaker selection..................................................................................................................................13
4.5. Charger alternator connections............................................................................................................14
4.6. 3-phase voltage and current wiring......................................................................................................16
4.6.1. 3-phase wiring, AGC 112.............................................................................................................16
4.6.2. 3-phase AMF wiring, AGC 113....................................................................................................17
4.7. 1-phase voltage and current wiring......................................................................................................18
4.8. Split-phase voltage and current wiring.................................................................................................19
4.9. Power management 3-phase wiring (AGC 145/146)............................................................................20
4.9.1. Mains breaker, AGC 145 ............................................................................................................20
4.9.2. Mains and tie breaker, AGC 146 ................................................................................................21

5. Communication
5.1. Wiring instructions................................................................................................................................22
5.2. Modbus RTU........................................................................................................................................23
5.2.1. Connection with 2-wire shielded cable (recommended)..............................................................23
5.2.2. Connection with 3-wire shielded cable........................................................................................24
5.3. CAN bus engine communication..........................................................................................................25
5.3.1. Connection with 2-wire shielded cable (recommended)..............................................................25
5.3.2. Connection with 3-wire shielded cable........................................................................................26
5.4. External I/O modules............................................................................................................................27
5.5. Additional Operator Panel, AOP-2.......................................................................................................28

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AGC 100 installation instructions General information
4189340752 UK

1. General information
1.1 Warnings, legal information and safety
1.1.1 Warnings and notes
Throughout this document, a number of warnings and notes with helpful user information will be presented.
To ensure that these are noticed, they will be highlighted as follows in order to separate them from the gener-
al text.

Warnings

Warnings indicate a potentially dangerous situation, which could result in death, personal in-
jury or damaged equipment, if certain guidelines are not followed.

Notes

Notes provide general information, which will be helpful for the reader to bear in mind.

1.1.2 Legal information and disclaimer


DEIF takes no responsibility for installation or operation of the generator set. If there is any doubt about how
to install or operate the engine/generator controlled by the Multi-line 2 unit, the company responsible for the
installation or the operation of the set must be contacted.

The Multi-line 2 unit is not to be opened by unauthorised personnel. If opened anyway, the war-
ranty will be lost.

Disclaimer
DEIF A/S reserves the right to change any of the contents of this document without prior notice.

1.1.3 Safety issues


Installing and operating the Multi-line 2 unit may imply work with dangerous currents and voltages. Therefore,
the installation should only be carried out by authorised personnel who understand the risks involved in work-
ing with live electrical equipment.

Be aware of the hazardous live currents and voltages. Do not touch any AC measurement in-
puts as this could lead to injury or death.

1.1.4 Electrostatic discharge awareness


Sufficient care must be taken to protect the terminal against static discharges during the installation. Once the
unit is installed and connected, these precautions are no longer necessary.

1.1.5 Factory settings


The Multi-line 2 unit is delivered from factory with certain factory settings. These are based on average values
and are not necessarily the correct settings for matching the engine/generator set in question. Precautions
must be taken to check the settings before running the engine/generator set.

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AGC 100 installation instructions General information
4189340752 UK

1.1.6 UL applications
These flat surface panel-mounted controllers are intended to be used in Listed Generator Assemblies, where
the suitability of the combination has been determined by Underwriters Laboratories.

1.2 About the installation instructions


1.2.1 General purpose
These Installation Instructions mainly include general product and hardware information, mounting instruc-
tions, terminal strip descriptions, I/O lists and wiring descriptions.

The general purpose of this document is to give the user important information to be used in the installation of
the unit.

Please make sure to read this document before starting to work with the Multi-line 2 unit and
the gen-set to be controlled. Failure to do this could result in human injury or damage to the
equipment.

1.2.2 Intended users


These Installation Instructions are mainly intended for the person responsible for the design and installation.
In most cases, this would be a panel builder designer. Naturally, other users might also find useful information
in the document.

1.2.3 Contents and overall structure


This document is divided into chapters, and in order to make the structure simple and easy to use, each
chapter will begin from the top of a new page.

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AGC 100 installation instructions Mounting
4189340752 UK

2. Mounting
2.1 AGC 100 mounting
The unit is designed for flush mounting by means of eight fixing clamps (IP52), which are included at delivery.
To have IP65, the unit must be ordered with option L (12 fixing clamps and a gasket).

2.1.1 Unit dimensions and panel cutout


The unit is designed for mounting in the panel front.

In order to ensure optimum mounting, the panel door must be cut out according to the following measure-
ments:

H W = 151.00 211.00 + 1.00 mm

H W = 5.94" 8.31" + 0.04"

220.0 (8.66)

Multi-line AGC 100

Alarm 1 0.3 Nm

Alarm 2

Alarm 3

Alarm 4
160.0 (6.30)

151.0 (5.94)

211.0 (8.30)
54.0 (2.13)
61.0 (2.40)

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AGC 100 installation instructions Mounting
4189340752 UK

2.1.2 Tightening torques

Unit panel door mounting: 0.3 Nm, 2.7 lb-in (see diagram in "Unit dimensions and panel cutout")
Plug connections (terminals): 0.5 Nm, 4.4 lb-in

AOP-1 and AOP-2 (see diagram below)


Panel door mounting: 0.7 Nm, 6.2 lb-in
Sub-D screw: 0.2 Nm, 1.8 lb-in
DC-DC converter terminals: 0.5 Nm, 4.4 lb-in

220.0 (8.661)

0.2 Nm
115.0 (4.528)

Display

9P Female
Sub 0
connector
0.7 Nm
Screw M3
Bossard BN5687 Max. 10 mm
or similar Min. 6 mm

20.0 (0.787)

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AGC 100 installation instructions Terminals
4189340752 UK

3. Terminals
3.1 Terminal overview and description
Unit rear view

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
+ -
Com

Com

MPU
Com
W/L

Com
Power

Emergency stop
Status Multi-functional

R21

R22
R23
supply inputs Binary inputs RPM inputs R24 R26
B(-) 49
RS485
Modbus GND 50
A(+) 51
52
CAN H 53

Service port CAN A Com 54


CAN L 55
56
CAN H 57
CAN B
Com 58
CAN L 59
Mains voltage Generator voltage Generator current GB MB
L1 N L2 NA L3 L1 N NA L2 NA L3 L1 L2 L3
28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

The RJ11 connector for the PC connection interface box is placed on the side of the unit.

3.1.1 Terminal description

For the relay outputs, the following terms will be used:


NO means Normally Open.
NC means Normally Closed.
Com. means common terminal for the individual relay.

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AGC 100 installation instructions Terminals
4189340752 UK

Terminal Technical data Description


1 Power supply + 6 to 36 V DC (UL/cUL Listed: 7.5 to 32.7 V DC)
2 Power supply GND
3-4 Status out/configurable See note*. Contact ratings 1 A 24 V DC/V AC Resistive
Multi-functional inputs
5 Common Common for terminal 6, 7 and 8
6 RMI/4 to 20 mA/digital input/ Configurable
Pt1000
7 RMI/4 to 20 mA/digital input/
Pt1000
8 RMI/4 to 20 mA/digital input
Digital inputs
9 Common Common for terminal 10 to 15
10 Digital input Configurable
11 Digital input
12 Digital input
13 Digital input
14 Digital input
15 Digital input
Tacho RPM input
16 RPM input (MPU) Magnetic pickup tacho generator (2-wire)
17 RPM-GND Common for RPM input
18 RPM input (W/L) Magnetic pickup. PNP, NPN or charge alternator W terminal
Relay outputs
19 Common Common for emergency stop terminal 20
20 Emergency stop and common Common for relay 21, 22 and 23 and input for emergency
for 21 to 23 stop**
21 Relay output Configurable. Function NO. Contact ratings 2 A 30 V DC/V
22 Relay output AC

23 Relay output
24-25 Relay output Configurable. Function NO. Contact ratings 8 A 30 V DC/V
26-27 Relay output AC

3-phase mains voltage input


28 Mains voltage L1 Mains voltage and frequency
29 Mains neutral
30 Mains voltage L2
31 Not used, must not be connec-
ted
32 Mains voltage L3

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AGC 100 installation instructions Terminals
4189340752 UK

Terminal Technical data Description


3-phase generator voltage input
33 Gen. voltage, L1 Generator voltage and frequency
34 Gen. neutral
35 Not used, must not be connec-
ted
36 Gen. voltage, L2
37 Not used, must not be connec-
ted
38 Gen. voltage, L3
3-phase generator current input
39 Gen. current L1, s1
40 Gen. current L1, s2
41 Gen. current L2, s1
Generator current
42 Gen. current L2, s2
43 Gen. current L3, s1
44 Gen. current L3, s2
Breaker relays
45 Relay output Generator circuit breaker/configurable, function NO (normal-
46 Relay output ly open)
Contact ratings 2 A 30 V DC/250 V AC
47 Relay output Mains circuit breaker/configurable, function NC (normally
48 Relay output closed). With "Option M19" the relay is NO.
Contact ratings 2 A 30 V DC/250 V AC
Modbus RS-485 interface
49 B (-)
50 GND Modbus RS-485 RTU or ASCII
51 A (+)
CAN bus port A: Engine interface
53 CAN-H
54 Com CAN J1939 engine communication
55 CAN-L
Optional CAN bus port B: AOP-2 interface
57 CAN-H
58 Com CAN communication line to AOP-2
59 CAN-L
Optional CAN bus port B: External I/O interface
57 CAN-H
58 Com CAN communication port to external I/O
59 CAN-L

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AGC 100 installation instructions Terminals
4189340752 UK

* The status relay is the uP watchdog output. This relay is normally energised, and the switch is closed after
power-up. If the uP fails or the power is lost, the relay will de-energise and the switch will open. If the unit fails
to start up at power-up, then the relay switch will remain open. The relay is configurable.

** If terminal 20 is used for emergency stop, please see wiring diagram below.

The relay output functions are configurable via the PC utility software and can, among many other functions,
be configured to cover the following in I/O settings:

Status OK
Run coil
Stop coil
Stop coil (not activated in start seq.)
Prepare
Starter(crank)
Horn
GB on
GB off
MB on
MB off

It is possible to choose run coil on one relay and stop coil on another, thus supporting engines with double
systems.

The multi-functional inputs can be configured to cover the following functions:

RMI sensor input


4 to 20 mA input
Binary input with wire break (switch function)
Pt1000

Tacho RPM input (MPU) can be configured to cover the following functions:

Magnetic pickup (2-wire)


NPN or PNP pickup*

* These RPM inputs require external equipment.

Tacho RPM input with capacitor (W/L) can be configured to cover the following functions:

Magnetic pickup (2-wire)


W terminal on charger alternator
NPN or PNP pickup*

* These RPM inputs require external components.

The generator voltage and current input can be configured to the following:

Voltage 100 to 25000 V primary


Current 5 to 9000 A primary

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AGC 100 installation instructions Wiring
4189340752 UK

4. Wiring
4.1 Wiring diagram

Charging Controller
alternator
D- D+ Running
12
1N4007 Programming
tool
Rex

27 R26
Alarm RJ11
26
plug
25 R24
Alarm horn Oli pressure
24 15
RUN coil Coolant temp.
23 R23 14
Starter Overspeed
22 13
R22
Start prep.
21
R21
Emer. STOP Remote start
20 11
Start enable
19 10
4 9
Status
3
F
- + - +
1
Battery
2

Term. 12 can be used as alarm input if not


used for charger generator terminal D+

Rex: 12 V systems: 47 4 W
24 V systems: 100 6 W

If a stop coil is used, the REX resistor can be connected to the starter relay (crank).

The illustrated configuration is an example of settings. The use of the relays can be chosen
freely.

It is important to protect the unit against damage caused by high voltages. Therefore, the fuse
must not be more than 2 A slow-blow.

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AGC 100 installation instructions Wiring
4189340752 UK

4.2 DC connections

* The illustration for the RMI sensors also apply to Pt1000 - but note that only multi-inputs 6 and 7 support
Pt1000.

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AGC 100 installation instructions Wiring
4189340752 UK

4.3 Digital inputs


All digital inputs are 12/24 V DC bi-directional optocoupler type. The typical wiring is illustrated below:

+12/24V DC

Bin IN

Common

0V DC

The digital inputs use fixed signals. Only the mode shift input and the test input (if the timer is
used) use pulse signal.

4.4 Breaker selection


The controller can handle pulse, continuous and compact breakers. Selection of the breaker type is done in
the application configuration with the PC utility software. Output for breaker handling is chosen in the I/O con-
figuration of the PC utility software.

In the table below it is listed which outputs are needed for breaker handling, depending on the breaker type.

Breaker type GB On/MB On/TB On GB Off/MB Off/TB Off


Pulse breaker X X
Continuous breaker X
Compact breaker X X

The pictures below are examples of how to set up breakers.

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AGC 100 installation instructions Wiring
4189340752 UK

Continuous breaker selection Pulse breaker selection


With GB On and MB On configuration With GB On, GB Off, MB On and MB Off selection

If the AGC 100 is ordered with option M19, relay 47 will have NO contact.

4.5 Charger alternator connections


The charger alternator can be used as running-feedback in two different ways:
1. Using the D+ terminal connected to terminal 12
2. Using the W terminal connected to the RPM input

Usually only one of these possibilities is used.

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AGC 100 installation instructions Wiring
4189340752 UK

Running
feedback
Run coil RPM
input
9 24 25 12 18 17

Rex
Battery
- +

1N4007

B+ D+ W

Brush
U V W

Charger Exciter
alternator coil (rotor)

Brush
Stator
Excitation
controller

Rex: Excitation resistor 12 V systems: 47 4 W


24 V systems: 100 6 W

At standstill, the battery + is connected to terminal 9 (common), and a current flows to terminal 12 and via the
D+ input on the alternator to ground (battery -). When the starter is engaged (cranking), the battery will supply
the D+ through the REX resistor, helping the alternator to excite. When the alternator starts to produce volt-
age (excitation OK), the speed of the alternator will be above running speed, and the voltage on term. 12 will
rise to a value higher than the battery voltage and then interrupt the current flow through REX and activate
the running feedback input. Engine is running.

If a stop coil is used, the REX resistor can be connected to the starter relay (crank).

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AGC 100 installation instructions Wiring
4189340752 UK

4.6 3-phase voltage and current wiring


4.6.1 3-phase wiring, AGC 112
Island operation

Consumer
N L1 L2 L3

Supply

45 GB ON
46 command

GB
14 GB OFF feedback

33 UL1
36 UL2 GENERATOR
34 N VOLTAGE

38 UL3

s2
40
I1
39
s1
s2
42
I2 GENERATOR
41 CURRENT
s1
s2
44
I3
43
s1

GENERATOR

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AGC 100 installation instructions Wiring
4189340752 UK

4.6.2 3-phase AMF wiring, AGC 113


3-phase AMF wiring

MAINS
N L1 L2 L3

28 UL1
29 N MAINS
30 UL2 VOLTAGE

32 UL3

Supply

15 MB OFF feedback

MB
47 MB ON
48 command

Consumers 45 GB ON
46 command

GB
14 GB OFF feedback

33 UL1
36 UL2 GENERATOR
34 N VOLTAGE

38 UL3

s2
40
I1
39
s1
s2
42
I2 GENERATOR
41 CURRENT
s1
s2
44
I3
43
s1

GENERATOR

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AGC 100 installation instructions Wiring
4189340752 UK

4.7 1-phase voltage and current wiring

Island, AGC 112 AMF and load takeover, AGC 113


N L1 MAINS
N L1
Supply

28 UL1
MAINS
29 N VOLTAGE

Supply
45 GB ON
46 command 15 MB OFF feedback

MB
GB 47 MB ON
14 GB OFF feedback 48 command
Consumers
45 GB ON
46 command
33 UL1

GENERATOR GB
34 N VOLTAGE
14 GB OFF feedback

s2
40 GENERATOR
I1 33 UL1
39 CURRENT
s1 GENERATOR
34 N
VOLTAGE

GENERATOR s2
40
I1 GENERATOR
39 CURRENT
s1

GENERATOR

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AGC 100 installation instructions Wiring
4189340752 UK

4.8 Split-phase voltage and current wiring

Island, AGC 112 AMF and load takeover, AGC 113


Consumer MAINS
N L1 L2 N L1 L2

Supply 28 UL1
29 N MAINS
30 UL2 VOLTAGE

Supply
45 GB ON
15 MB OFF feedback
46 command
MB
47 MB ON
GB
48 command
14 GB OFF feedback Consumers
45 GB ON
46 command

33 UL1
GB
36 UL2 GENERATOR
VOLTAGE 14 GB OFF feedback
34 N

s2 33 UL1
40
I1
39 36 UL2 GENERATOR
s1
s2 34 N VOLTAGE
42
I2 GENERATOR
41 CURRENT
s1

s2
40
I1
39
s1
s2
42
I2 GENERATOR
41 CURRENT
s1
GENERATOR

GENERATOR

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AGC 100 installation instructions Wiring
4189340752 UK

4.9 Power management 3-phase wiring (AGC 145/146)


4.9.1 Mains breaker, AGC 145

BUSBAR
N L1 L2 L3

28 UL1
29 N BUSBAR
30 UL2 VOLTAGE

32 UL3

Supply

Consumers 45 MB ON
46 command

MB
14 MB OFF feedback

33 UL1
34 N MAINS
36 UL2 VOLTAGE

38 UL3

s2
40
I1
39
s1
s2
42 MAINS
I2
41 CURRENT
s1
s2
44
I3
43
s1

N L1 L2 L3

MAINS

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AGC 100 installation instructions Wiring
4189340752 UK

4.9.2 Mains and tie breaker, AGC 146

BUSBAR
N L1 L2 L3

28 UL1
29 N BUSBAR
30 UL2 VOLTAGE

32 UL3

Supply

15 TB OFF feedback

TB
47 TB ON
48 command

Consumers 45 MB ON
46 command

MB
14 MB OFF feedback

33 UL1
34 N MAINS
36 UL2 VOLTAGE

38 UL3

s2
40
I1
39
s1
s2
42 MAINS
I2
41 CURRENT
s1
s2
44
I3
43
s1

N L1 L2 L3

MAINS

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AGC 100 installation instructions Communication
4189340752 UK

5. Communication
5.1 Wiring instructions
Cable
Belden 3106 A or equivalent. 22 AWG (0.324 mm2) shielded twisted pair, min. 95 % shield coverage.

Cable shield
Connect the cable shield to earth at one end only.

GND terminal connection


In case of communication problems, the GND terminals of the unit and the external device can be linked to-
gether using a third wire.

CAN bus termination resistor


The size of the terminating resistors should be 120 1 %, 0.5 W resistor.

Never connect the GND terminal to earth directly or through the shield!

If the GND terminal is connected to a PLC or other device, the GND connection of this device
must be isolated from earth!

Maximum length of the CAN bus line is 400 m.

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AGC 100 installation instructions Communication
4189340752 UK

5.2 Modbus RTU


5.2.1 Connection with 2-wire shielded cable (recommended)

Multi-line 2 Multi-line 2 Multi-line 2


DATA + (A)

DATA (GND)

DATA - (B)

DATA + (A)

DATA (GND)

DATA - (B)

DATA + (A)

DATA (GND)

DATA - (B)
29 30 31 29 30 31 29 30 31
DATA - (B)

DATA (GND)

DATA + (A)

PLC or other device

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AGC 100 installation instructions Communication
4189340752 UK

5.2.2 Connection with 3-wire shielded cable

Multi-line 2 Multi-line 2 Multi-line 2


DATA + (A)

DATA (GND)

DATA - (B)

DATA + (A)

DATA (GND)

DATA - (B)

DATA + (A)

DATA (GND)

DATA - (B)
29 30 31 29 30 31 29 30 31
DATA - (B)

DATA (GND)

DATA + (A)

PLC or other device

For wiring details, please refer to "Wiring instructions" in this section.

In case of very long lines on the network, terminating resistors might be needed (typically 120
1 %, 0.5 W).

The calculation should be based on the following data:


A line internal pull-up bias resistor: 22 k
B line internal pull-down bias resistor: 22 k
Receiver input sensitivity: +/-200 mV
Receiver input impedance: 12 k

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AGC 100 installation instructions Communication
4189340752 UK

5.3 CAN bus engine communication


5.3.1 Connection with 2-wire shielded cable (recommended)

Multi-line 2
CAN-H

Com

CAN-L

53 54 55

R
CAN-L

Com

CAN-H

ECM
engine control module

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AGC 100 installation instructions Communication
4189340752 UK

5.3.2 Connection with 3-wire shielded cable

Multi-line 2
CAN-H

Com

CAN-L

53 54 55

R
CAN-L

Com

CAN-H

ECM
engine control module

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AGC 100 installation instructions Communication
4189340752 UK

5.4 External I/O modules

AGC 100

Option H8

120

120
CAN-H
57

58
CAN-L
59

I/O RUN

I/O EER

BECKHOFF
ON
1 2 3 4 5 6 7 8

For wiring details, please refer to "Wiring instructions" in this section.

If external I/O modules "Option H8" are used together with AOP-2, the total terminal resistance
of the AOP-2 and the external I/O controller must be 120 .

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AGC 100 installation instructions Communication
4189340752 UK

5.5 Additional Operator Panel, AOP-2

Additional operators panel AOP-2

App./Bootl.
End res.
CAN L CAN H
57 OFF CAN 1 CAN 2
59
ON

R=120

Black/white

Brown/white
Brown/white

Black/white
Red/white
Red/white
Black

Brown
Black
Red
Red

-+
5V DC
Terminal block DIN rail
24V DC
1 2

Common
NO
NC
-+
Comm. to
Cable shield next units

Status relay
1...6 1...6

6 - Black: GND 6 - Black: Relay common


5 - Black/white: +5V DC 5 - Black/white: Relay NO
4 - Brown: Not used 4 - Brown: Relay NC
3 - Red: CAN L 3 - Red: CAN L
2 - Brown/white: CAN GND 2 - Brown/white: CAN GND
1 - Red/white: CAN H 1 - Red/white: CAN H

Left CAN port (CAN 1) Right CAN port (CAN 2)

For wiring details, please refer to "Wiring instructions" in this section.

If external I/O modules "Option H8" are used together with AOP-2, the total end resistance of
the AOP-2 and the external I/O controller must be 120 .

A DC/DC converter for the DC supply voltage and 2 1 m cable with an RJ12 plug in one end
and stripped wires in the other end are included in the AOP-2 delivery.

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